Floor covering and process of preparing the same



106' CQMPOSTHONS, 4 Gross HBTBTBHCB Examinez comma 0R PLASTlC Feb. l J. 'r. BALDWIN 1,793,667 f; FLOOR covmnme AND PRocE'ss OF PREPARING THE sum Original Fi1ed Jan.'8, 1927 Patented Feb. 24, 1931 UNITED STATES PATENT OFFICE JULIAN T. BALDWIN, OF WEST CHESTER, PENNSYLVANIA, ASSIGNOR TO SANDURA oomrany, INCL, OF PHILADELPHIA, PENNSYLVANIA, A CORPORATION OF NEW JERSEY FLOOR COVERING AND PROCESS OI PREPARING THE SAME Application filed January 8, 1927, Serial No. 159,918. Renewed Ia This invention relates to an im rovement in floor coverings and to a process or making the same.

The present invention is a substitute for have the plasticizer as the 1 ernal phase or in solution in the resin. The solution is probably not a true solution but a gel or a dispersion of plasticizer in the resin.

linoleum. In place of the oils and gums now Plasticizers are generallymd and have fnl// used for the binding medium which holds the pm vapor pressure at ordinary cork and wood floor together, it is proposed temperatures F They are hi h boil- -to use a composition which has certain adin oint solvents for resins, thelr bollmg m vantages. For example, the proposed bind- IJOIIXES ranging not much below 300 C.; they 0 ing agent makes it possible to manufacture a fioor covering in -twenty-four hours or less whereas to make the present linoleums, it requires much longer periods, sometimes as long as six months, three months to oxidize the oil by the scrim process and three months'to cure the manufactured linoleum.

are chemically stable; free from tackiness; and impart to the resins the important properties of flexibility, toughness, impermeability, durability and smoothness of surface.

Examples of plasticizers arezdieth l htha ate dibutyl Ehthalate, diam l liilialate- B5 1 u ar ra e, r1 en 0s a e and Even for the light grades of llnoleum, several tricres pligsphafi. weeks are required. Modifiers are used optionally to attain cer- O. The bindin a ent employed in the'floor tdln desired qualities such as hardness, elascovering of the present invention is a soticity, cheapness, and impermeability. -Modi- I called resinlasticizer com osition, the defiers are distinguished from the body ingreditails of wfilcli' are described and claimed in cuts in that they-are a part of the gel or bindmy co ending application Serial No. 138,897, ing medium and are not merely bound by the W filed ctober 1, 1926, and consists generally gel. Similar substances may be used both as of resino substances, lasticizers, and opmodifiers and as body ingredients. Cellulose tiona y mo xfiers. ucii a composition is esters for example could be a part ()Ttlieigelmore fiGXlBlG, tougher, more durable, and less and at the same time be present in the form permeable than linoleum.- It is more resistof lumps that are bound by the gel. Resins an ant to the soaps and alkalies used for cleaning may also be a part of the gel and at the same than is the common linoleum, since the latter time be present in the form of undissolved contains vegetable oils that are saponifiable lumps. Modifiers may include cellulose esters 3 and subject to attack. and ethers, rubber h drocarEons, s lnacene, The resins employed may be either natural s ualene, waxes filtclies, ol merlzed OllS s. In a 1t1on,

or szntliggg. examples of which are acrolaes'- an an i 0 1n ica e. or -\.l a 1 um, rosin. Man a. copal, shellac, cumaron, water lass has been form o give goo reeste r m, urea ormm d e resins, an e su s as a modifier. Its chief purpose is to like. It is to Be understood that By resin is harden. When used in excess, it becomes a meant a true resin as technically distinfiller also, for it has been observed that the guished from a gum. A true resin, for inbinding agent holds but a certain amount,

stance, is insoluble in water, whereas a gum and the excess separates out. is soluble 1n wateg. The bod in edients used with the binding lasticizers are substances or mixtures of medium are any suERances which are suitable P 2 substances which apparently form a permafor use in floor coverings, for example, cork :15 nent gel or state of solution with resins. 'dust, wood flour, ru'bber, cellulose esters in When a plasticizer is mixed with a'resin, the lastic lum form, viscose, ox c ll l s resulting composition is generally considsroceflulosefi cellulose fibers, h Era (i lulose stare me fier'ize' and vumdd ve etable 01E? igm cuts, and

ered to be a solution of the resin in the plasticizer, the. plasticizer being the external ers.

. 1 phase. It is desirable in the present case to miner A general formula for a J is as follows:

Specific examples. of bindin a ents are as follows:

bindigg megiggi Parts by weight Resinous substances 100 Plasticizers L 35 Modifiers my be added and solvents maybe use ut the use of heat to render the mass workable is desirab e. uch solvents as denatured alcohol, benzol, toluol and naph'tliz? 111:) 5'5 used \Yllel'l necessary.

Parts by I weight Rosin 100 Dibntyl phthalate 35 2 Sodium silicate 4 Nitrocellulose 4 Castor oil 2 A dye may be added to the plasticizer which is added to the melted resins.

. Parish weight Ester gum 50 Cumaron resin i 50 a0 Dibutyl tartrate Polymerized linseed oil 10 Parts by weight 35 Urea formaldehyde resin 5O Cumaron resin 25 Rosin 25 Tric'resyl phosphate 20 Dibntyl phthalate 20 The exemplified above are hea e an whiYin a softened condition are g' round with the various bod in edients in pl'op'er proportions. Generally about one The hardening or curing period is much shorter than that used for linoleum, only a few hours being necessary for the heated to harden as they are cooled. The resulting product may be used to make a product similar to inlaid linoleum or it may be used as a. base upon which a decorative coat is applied. The important difierences between the manufacture of the floor covering of this invention and the manufacture of linoleum, are that the binding medium in the former case is prepared by heating the resins, plasticizers and modifiers, instead of going through a laborious and complicated process of oxidizing oils and mixing with resins. Furthermore, the drying or curing process consists merely of the hardening of the resin-plasticizer composition instead of slow oxidation as in the case of an oil binding agent.

What I claim is 1. A floor covering consisting of a plastic composition mounted on a support, the said plastic composition including a resin, a plasticizer for the resin, and body ingredients.

2. A floor covering consisting of a plastic composition mounted on a support, the said plastic composition including a resin, a plasticizer for the resin, :1. modifier, and body ingredients.

' 3. A floor covering consisting of a plastic composition mounted on a support, the said plastic composition including a resin, diamyl phthalate, and body ingredients.

- 4. A floor covering consisting of a. plastic composition mounted on a support, the said 1 part of binder is used with one part ofihody hot, to a support, and cooling the resulting 45 ingredlents, but these proportions are subee 0 variation, dependin upon the degree esired. The fol- The mixture of binding medium and body inglredients Bis then rcim between calendar ro ers and y t an ressure or ressure alone is fasteni$b a slmch iis, burlap or a bitumen saturated felt. The drawing accompanying this application represents a cross sectional view of a floor covering which consists of a layer 1 .of the above described binding agent mixed with suitable body ingredients ,and coloring material attachedto any suitable support 2 which may or may not be impregnated with any suitable material.

' of hardness or resiliency lowmg isan' example:

product.

6. A process for making a floor covering, the said process consisting in grinding together body ingredients, a resin, and a plasticizer for the resin, keeping the mixture hot, spreading the material over a fibrous support by means of pressure rolls, and cooling the resulting' product. u

7. A process for making a floor covering, the said process consisting m mixing body ingredients with a binding agent comprising a resinand a plasticizer for the resin, and by means of pressure, attaching the resulting composition, in the form of a layer, to a fibrous support.

In testimony whereof I afiix my signature.

- JULIAN T. BALDWIN. 

